Products & Solutions

Heating & Hardening

Heating division of Electrotherm has supplied more than 650 equipment to Forging and heat-treatment industry. The products offered are Ferrous & Non-Ferrous Billet Heating, Extrusion, Rolling, Soldering, Brazing, Heat Treatment including case hardening, Tempering and Annealing, Shrink Fitting, Strip Heating, Tube & wire heating, Continuous Annealing, Stress relieving etc…

Induction Heating

Induction heating is a process which is used to bond, harden or soften metals or other conductive materials. For many modern manufacturing processes, induction heating offers an attractive combination of speed, consistency and control.

Long Bar Heater - Induction Heating Equipment for Various Applications

Customer Benefit

  • Instant and fast heating.
  • Precise temperature control
  • Eco-friendly heating.
  • Minimize down time.
  • Less rejection of material.
  • Space saving.
  • Minimize scale loss.
  • Process control.
  • Due to uniform heating die life will get increase.
  • Due to automation requirement of man power will be less.
  • Energy saving with greater quality.
  • Maintenance free and easy to Installed.
  • Greater thermal efficiency.

Applications

  • Automotive
  • Aerospace
  • Industrial
  • Mining
  • Oil and gas
  • Marine
  • Railway
  • Construction
  • Power Generation
  • Agriculture

Forging & Forming

Forging and forming process consist of a part that has been previously heated to a temperature at which its resistance to deformation is weak. The forging temperatures of the most commonly used industrial materials are:

  • Steel 1100 to 1250 ºC
  • Brass/Copper 800 to 900 ºC
  • Aluminum 300 to 480 ºC

HNH Billet Heater - Induction Forging Furnace for Steel, Copper & Aluminum

After heating up the material, the forming operation is done on different types of machines like mechanical presses, hydraulic presses, hammer, ring rolling etc. Materials used for forging are in shape of rounded bar, square billet.

The process of forging and forming is a common process in the manufacture of many industrial sectors such as automobile, railway, aerospace, and forging.

Advantages

  • Labour savings through high degree of automation
  • Small space requirement
  • Eco-friendly and emission-free
  • High operational reliability and availability

Equipment Rating

  • Power: 50 kW to 1000 kW
  • Frequency: 500 Hz to 100 kHz

Extrusion

Extrusion is a process used to create objects of a fixed cross-sectional profile. A material is pushed or drawn through a die of the desired cross-section. The extrusion process can be done with the material hot or cold. Extrusion may be continuous or semi-continuous. Materials required for this process is mention below

  • Brass/Copper 600 to 1100 ºC
  • Aluminum 350 to 500 ºC

Advantage

  • lack of oxidation
  • Higher strength
  • Closer tolerances
  • Better surface finish

Equipment Rating

  • Power: 50 kW to 1000 kW
  • Frequency: 500 Hz to 100 kHz

Brazing

Brazing is a process in which two or more materials are joined together by a filler metal that has a lower melting point than the base materials using induction heating. In brazing application joining of two pieces is done by process of using heat and a filler material that melts at a temperature above 427 ºC (800 ºF) and below the melting point of the parts to be brazen.

The filler metal used in brazing varies depending on the parts being joined. The most preferred alloys are phosphor copper, silver, nickel and cobalt, aluminum, silicon, copper, copper-zinc and magnesium.

In this process same material or different materials is permanently bond with high strength, simplify mechanical operation and adopt simple production techniques, always compatible with the demands of mass production among others.

Advantages

  • Improved process efficiency
  • Fast and localized heat
  • Temperature control
  • Creation of clean joint, precise and controllable
  • Clean and technologies
  • The process eliminates the distortion and other undesirable metallurgical changes in different regions of the work pieces

Application

  • Cookware Bottom Brazing (Sandwich/Capsule Brazing)
  • Rotor Brazing

Equipment Rating

  • Power: 50 kW to 1000 kW
  • Frequency: 500 Hz to 100 kHz

In-Line Induction heating system for hot rolling

See Video1  Video2

Eletrotherm’s In-Line Induction heating system for hot rolling/ reheating of bars, billets, slabs, plates, and blooms. Our heater provides temperature control and uniform heating from surface to core and head to tail of the product. Our heater is highly efficient and compact; available in frequencies between 50 Hz to 6000 Hz. and power between 500 kW to 10000 kW. Hot rolling is used to form thinner pieces of metal by using heat.

Inline Induction Heating System for Billet, TMT bar, Angle, Channel, I-beam & Wire Rod

This process is mainly used to change the shape and thickness of a metal. The starting material is usually large pieces of metal, like semi-finished casting products, such as slabs, blooms and billet. If this product came from a continuous casting operation the products are fed directly into the rolling mills at the proper temperature.

Steel slabs or billets are first heated to an extreme temperature, which is slightly above the metal’s recrystallization temperature, and then they are sent through rollers that can be programmed to apply a controlled amount of pressure to form the metal into the desired size or thickness.

Hot rolling is used mainly to produce sheet metal or simple cross-sections such as rail tracks. Other typically uses of hot rolling is to produce TMT bar, angle, channel, I-beam and wire rod.

Advantages

  • Quick slab heating throughput
  • High heating efficiency
  • In-line or oscillating heaters
  • Closed loop temperature control
  • Reduced maintenance
  • Reduced scale formation
  • Highly compact installations

Pipe & Tube Heating

Induction heating is preferred solution for pipe & tube manufactures looking for more effective, cost-efficient heating technology. Whether you are involved in hot bending, weld stress relieving, heat treating and coating or brazing, induction heating may be the approach for your operation.

Induction Heating Equipment for Pipe & Tube Manufacturers

Applications

  • Pipe and Tube Coating.
  • Pipe and Tube End Heating.
  • Pipe and Tube Annealing.

Shrink Fitting

Shrink fitting process refers to avoids the changing of mechanical properties whilst allowing components to be worked. Metals typically expand in response to heating and contract on cooling; this dimensional response to temperature change.

Strip & Pot Heating

Electrotherm’s induction technology is providing the answer to many modern strip processing quality and production problem. Induction heating is an advanced method to heat thin metal products like iron, stainless steel and special alloys. Continuous strip heating with strategically placed heating coils that accurately control temperature cycles using only a fraction of the space of conventional heating methods.

Application

  • Strip Galvanizing
  • Hot dip Galvanizing
  • Galvannealing
  • Edge Heating
  • Strip Coating

In-Line Induction cast bar heating (Al./ Brass/ Copper Conductor)

In-Line induction cast bar heating equipment is installed before the hot rolling unit heating coils are designed as per the job size (round/square/trapezoidal). Useful in conductor, cable and wire rod mill. With continuous heating lines save thousands of energy dollars by utilizing induction heater and restoring only the additional energy required to reach optimum rolling temperature.

Advantages

  • Low energy consumption
  • Higher productivity
  • Less space requirement
  • Need less maintenance and easy to operate
  • Uniform and precise temperature control
  • Elimination of stress relieving process prior to wire drawing

Cable & Wire Heating

The production of optical fiber conductors and cables requires continuous heat for preheating, polymerization and sealing of the insulator, annealing, covering, etc. Because of its compact footprint and precision temperature control, Electrotherm’s induction heating equipment is the ideal solution for these processes in steel, copper, aluminum, brass materials.

Induction Hardening

Hardening is a process of increasing the hardness and mechanical strength of steel. Steel is heated to a temperature slightly higher than the upper critical (between 850-900ºC) and then cooled more or less quickly (depending on the characteristics of steel) in a quenching medium such as oil, air, water, water mixed with soluble polymers, etc.

Normally steels are used in induction hardening contain from 0.3% to 0.7% carbon (hypoeutectic steels).

Induction Hardening Equipment for Steel

Advantages

  • Specific parts of the material to be harden.
  • Frequency Control and heating times
  • Energy saving
  • Cooling control
  • Increase performance and saves space

Case/Surface/Face Hardening

Case or surface hardening is the process of hardening the surface of a metal object and thus forming a thin layer of harder metal at the surface. For iron or steel with low carbon content, which has poor to no harden ability of its own, the case hardening process involves infusing additional carbon into the case. Case hardening is usually done after the part has been formed into its final shape, but can also be done to increase the hardening element content of bars to be used in a pattern welding or similar process.

Because hardened metal is usually more brittle than softer metal, through-hardening (that is, hardening the metal uniformly throughout the piece) is not always a suitable choice for applications where the metal part is subject to certain kinds of stress.

 

  • Through Hardening
  • Roll Hardening
  • Rail Hardening
  • Gear Hardening
  • Machine tools Hardening
  • Automobile parts Hardening
  • Center Pivot Hardening
  • Tempering

TESTIMONIALS